Apparatus for producing castings



Dec' 29, 1942- J..E. JOHNSON l 2,307,001

APPARATUS FOR PRODUGING CASTINGS Filed April 18, 1940 2 Sheets-Sheet 1 32 a@ /ffa .7L @g5 Y I 77 Dec. v29, 1942. J, E, JOHNSON v 2,307,001

APPARATUS FOR PRYODUCING CASTINGS Filed April 18, 1940 2 Sheets-Sheet 2 9L, I 6g ,Ami ",nmfg., 'l /qm "7 www n fg wu 70 go x w; 74 10d Y Kmme.. e 76 19 57 E 75 72' ..."u'; '55 n INVEN-roRA IWW/l .fd/171.5071,

ATTORNEY;

Patented Dec. 29, 1942 UNITED STTES ATENT OFFICE APPARATUS FOR PRODUCING CASTINGS Joseph E. Johnson, Brooklyn, N. Y. Application April 18, 1940, Serial No. 330,287

9 Claims.

This invention has for its principal object the production of a machine for producing in an ex- Y peditious, facile and novel manner an exact and faithful reproduction or facsimile of an object, such as an insignia, inscription, cameo, intaglio etc., which has been placed in a die or which forms a part thereof. Theinvention is peculiarly adapted in its application to metals having a high melting point.

Further and other objectsof the invention will be apparent as the description thereof proceeds.

According to the preferred form of the invention, the metal as, for instance, steel or other material from whichv the casting isto be formed, is employed in the process in shaped or block form, as a rodor bar or a disc or roller and a portion thereof is fused or broughtA to molten or liquid state by the application of heat, such for instance, by means of the well known electric arc method in which the metal material itself forms one of the electrodes. The end of the rod or bar, or if a disc or roller is employed, its periphery isthen fused and forced quickly in molten condition into the die and pressure isthen applied to the molten metal within the die, the pressure-applying means preferably being the unmolten or relativelyr cool portion of the metal Work or material itself.

In the several figures of the accompanying drawings showing. a practical embodiment of 'the apparatus of the invention.:

Fig. 1 is a top plan View of such apparatus.

Fig. 2 is aside elevation thereof.

Fig. 3 is a vertical cross-section on the line 3"--3 of Fig. 2.

Fig. 4- is a horizontal cross-section on the. line 4-4 of Fig. 3..

Fig. 5 is a sectionalview of a modification taken on the line 5.-5 of Fig. 6, and

Fig. 6 is a vertical cross-section of the modiication taken on. the line I--G of Fig. 5.

Referring in detail to the drawings and, for the present, more particularly to Figs. l. to: 4 i'n`- elusive:

A walled. chamber within which the processv of the invention is carried on is indicated at. I0. Said charn'ber'isA providedv with a base II, a. front wall I2 detachably secured to thel chambenasby screws I3, whereby access to the interior of the chamber may readily be had, and anV inwardly extending annular flange as shown forming a bearing member for a work-holder as Awillv be herein described. A rotatable work-holder is indicatedat I5 and carries thework. I6 fromwhich the castingisto beformed.v Ixrtherpreferredform of the invention the work comprises a rod of suitable fusible and preferably metallic material, such as steel. This steel rod extends downwardly through the work-holder and into the' chamber, as shown, and it is slidably andi adjustably held in said work-holder in any desirable manner, as by set-screw I1 passing' through the work-holder into engagement with the rod I6.

The upper end of the work-holder I5 is reduced in character as at I8' and extends through and is joi'irnalled'v within a cross-bar I9. The ends of said cross-bar are provided with guiding pins 20 slidably received within slots 2|v of angled verticalsupporting arms 22, the anglesr of' which are detachably secured to the upper portion or wall of the chamber by means of adjustable screws 23. Tension springs 24 arev connected to saidscrews and to the cross-bar I9 andy constantly urge movement of the cross-bar i5 downwardly and accordingly movement of the work-holder I5 in the same direction withl the guiding. pins 20 engaging with the slots' 2l. A` ball-race 25 may be provided and is interposed between the cross-bar |19 and work-holder I5 to decrease the effect of friction between the cross-bar I9 andi work-holder I5 when the latter element is rotated. To permit connection between the cross-bar I9 and workholder I5 While permitting rotation of the' latter, I. have provided a strap 25 fastened to the crosse bar' and slidably engaging beneath an annular flange' 25 with which the work-holder ispro- Vded';

A rotatable sleeve'is indicated at 26. Said sleeve is' rotatably journalled' within an inwardly ex-y tending flange or wallf 21 herein` before referred to and preferably integral with the' side walls of the=chamb`er I Il andy it isprovided with an annular sleeve 28.L acting: asy a stop to limit the upward vertical: movement of said sleeve within` -said flange or wal-l 2T. The sleeve 26 and work-holder I5 are splined together by meansw of a` key 29 ony the sleeve' whichv enters a slot 30 in thel workholder'.. This connection permits verticalA movement downwardlyv of the work-holder I5 within the sleeve but prevents relative' rotation of one member with respect' to the other.

The upper end of thesleeve 26 is provided with a toothed gear orf pinion 3I detachably fastened thereto in any desirableY manner' whereby it is ro tatable with said sleeve. The teeth of thepinion 3| mesh with the teeth of a slidable rack 32y guided in its movementby` anagle-bar 33 fastened to a wall of` the chamber; One endof the rack is adaptecl-l to enter" a suitable slot 3'4- in' a wall of the chamber' and? the other endhas a shank 35 journalled in and extending through an opposite wall and terminating in an operating handle 36. Obviously, reciprocation of the rack 32 by the handle 36 will rotate the sleeve 26 and consequently the Work-holder I which carries the rod I6 with it.

A slidable die-support, slidable on the base II, is indicated at 31. Said support detachably carries a metallic die 36 thereon which contains the impression from which the casting is to be made. In its base the die is provided with suitable openings for frictionally receiving pins 39 whereby removal and substitutions of different dies may` readily be made with facility after removal of the detachable front wall I2. received in an opening in a wall of the chamber and the opposite wall is provided with a screwthreaded opening receiving an adjustable screw 46. Said screw acts as a stop to limit the move. ment to the left (Fig. 3) of the support 31 on the base II and by adjusting said screw, the die may be brought into exact vertical alignment with the rod I6.

Anactuating rod or bar is indicated at 4I and terminates in a handle 42. Said rod is pivoted at 42', as shown, to a bracket 43 fastened to a wall of the chamber and it is also connected by a pin and. slot connection 44 to the die-support 31. A horizontally slidable rod comprising an electrode is indicated at 45. by an insulating bushing 46 mounted in a Wall of the chamber and it is pivotally connected to the end of actuating rod 4I by a pin and slot connection 41. Insulating material surrounds this lastnamed connection, as illustrated, to prevent short circuiting.

A bracket 48 is mounted on a wall of the housing and has an arm 49 pivoted thereto as at 46. The lower end of said arm 49 engages a lug or projection 5I) made of an insulating material and carried by the rod 45. The upper end of said arm 49 is connected by a pin and slot connection 5I to a locking arm 52 journalled in a wall of the housing and terminating at its inner end in a locking member 53 having an opening 54 of a size permitting it to normally loosely receive the workholding member I5. One side of the opening 54 is beveled as at 55 and is adapted to be received by an annular notch 56 in the member I5 to hold and detachably lock it in elevated position against the action of the springs 24. A compression spring 56 is interposed intermediate the arm 43 adjacent its upper end and a wall of the chamber and urges said arm to swing in a clockwise di- 'rection to retain the member I5 in raised and locked position.

' A binding post is indicated at 51 and is provided with a shank entering a bore 58 extending through a wall of the chamber. A compression spring 59 is mounted in said bore intermediate the shank of the binding post and a terminal 60 also mounted in the bore and having wiping electrical contact with the sleeve 26. A conductor 6I is fastened to the binding post 51 and is connected to a source of current supply (not shown) while another conductor 62 is also connected to said source of current supply and to the electrode 45. The apparatus is shown in inoperative position with the metal die 38 shielded by a bale plate 63 to prevent the introduction of dirt or other forengn matter into the die and which may be formed as an integral part of a wall of the chamber. I have also provided means for visual inspection of the end of the rod I6 in order to in- Spect its physical condition while being subjected The die-support isl Said rod is slidably received to the fusing process. Said means comprises a tube 64 extending through -the wall I2 and in horizontal alignment with the end of the rod I6. Mounted on the outer end of said tube exteriorly of the chamber is a head 65 carrying a transparent plate 66, preferably of glass. This arrangement prevents the entrance of air into the chamber which is desirable in some cases as I have often found it expedient to carry on operations within the chamber in a vacuum or partial vacuum to prevent scaling of the rod I6 or the casting to be formed therefrom and which also enhances the fusing operation by the electric arc method.` Y

Assuming the parts are in the positions shown, the operation of the apparatus is as follows:

The rod 4I is thrown to the right on its pivot 42. (Fig. 3) in order to bring the inner end of the electrode into contact with the lower end of the rod I5 to establish the completion of the electrical circuit through the end of the rod and the electrode. The rod 4I is then moved slightly to the left or in a clockwise direction to space the end of the rod I6 and the end of the electrode 45 whereby an electric heating arc between the members is established. Meanwhile fusing of the end of the rod I6 proceeds and while so proceeding the rack 33 is reciprocated backwardly and forwardlly to thereby rotate the rod in an obvious manner and thereby secure a uniform fusion thereof at all places adjacent its lower end. When said end has reached the necessary degree of plasticity as determined by visual inspection thereof in the manner previously described, the rod or bar 4I is thrown completely to the left on its pivot in a clockwise direction and as indicated at the left in dotted lines in Fig. 3. This, obviously carries the die 3B on its support 31 into vertical alignment with the end of the rod I6, retracts the electrode 45 and releases the locking edge from its engagement with the notch 56 whereby the work-holder I5 slides downwardly within the sleeve 26, assisted by the action of the springs 24, and the molten metal on the end of the rod I6 is brought within the die 38 and isv compressed therein by the unfused or unmolten part of said rod I6 to form the casting which con-Y forms in configuration to the inner configuration of the die 38. After the casting is so formed and sufficiently cooled, the workeholder I5 carrying the rod I6 with the formed casting on the end thereof is manually raised by means of the crossbar I9 to its initial position and locked in that position by swinging the rod or bar to inoperative or vertical position shown in full lines in Fig. 3 to' permit the action of the spring 56 to bring the holder I5 and locking member 53 into interlocked engagement. The formed casting may then be out off from the end of rod I6 at desired length. As the operating length of the rod I6 becomes shortened because of successive operations and the fusing of its end and the formation of su'ccessive castings, it maybe lengthened by loosening the set-screw I1 and forcing the rod downwardly within its holder. It will be found that castings produced by the process described herein do not require re-hardening as they are sufIi ciently hardened by the quick cooling effect of the metallic die 38. This sudden chilling of the softened metal on the end of the rod I6, furthermore, prevents' it from sticking to thedie as is obvious.

In the modification illustrated in Figs. 5 and 6, the metal or other material from which the casting is formed is preferably in the form of a disc or roller indicated at $1 and is detachably mounted in any manner on a separable or two-part shaft 68 the ends of which are journalled in opposite walls of the chamber. The casting in this case becomes a part of the peripheral edge of said disc or roller. The shaft is prevented from horizontalmovement in one direction by a Washer and set-screw indicated generally at 69 and the other end of the shaft is provided with a crank 18 for the purpose of rotating it. The die 'll is slidable and extends within suitable slots 'l2 formed in the body of the chamber and which guide the die in its movement. Said die is grooved as at 'I3 in its face or side adjacent the disc or roller 61, said groove containing the object or inscription etc. which it is desired to reproduce by a casting. A bracket 14 is fastened to a wall of the chamber and a bar or rod 'l5 is pivoted thereto, as by pivot 16. The upper end of said bar is connected by a pin and slot connection 'il to a detent slide or rod 18 extending through an opening in a wall of the housing vwhich slidably supports it. The inner end of said detent slide normally engages beneath the end of the die 'H to hold it in inoperative or retracted position.

A rod 18 is secured to the upper end of the die 'li or it may be integral therewith. Secured to the said rod 'i9 is a cross-arm 88 and tension springs 8| are fastened to said cross-arm adjacent :2

its ends and to an upper Wall of the chamber. v'Ihe action of said springs 8| tends to slide the die ll downwardly within the slots 'l2 as is obvious.

The bar or rod terminates at its lower end in a handle 32 and said bar or rod is connected by a pin and slot connection B3 to an angle bar, the horizontal leg of which is indicated at 84 while its vertical leg is indicated at 85. The vertical leg 85 may be supported by a pin or bolt 86 extending loosely therethrough and into the body of the housing and a compression spring 81 encircles said pin or bolt and bears against said leg and housing and tends by its action to retain said leg a spaced distance from said housing.

A pin and slot connection 88 connects the upper end of the leg 85 to an electrode 89 slidably mounted in an insulated bushing 90 in a wall of the chamber, said pin and slot connection being surrounded by insulating material as in the previous case. A conductor 9| is connected to a source of current supply and to the outer end of electrode 89 while conductor 92 is connected to the same source of current supply and to a Wall of the chamber.

As in the previous case, the handle 82 is manipulated in the proper direction to bring the inner end of the electrode 89 into Contact with the periphery of the disc or roller 61 to establish the electrical circuit. It is then again manipulated slightly to space the roller from the end of the electrode whereby a heating electric arc is made to fuse the peripheral edge of the disc or roller. When the proper degree of plasticity of such edge has been reached the handle is swung in such manner as to release the detent 18 from engagement with the die or mold 'Il which travels downwardly under the influence of springs 8| and the fused metal on the peripheral edge of the disc or roller e? enters the groove 13 in the die to form the desired casting on the edge of the disc, the unfused and comparatively cool portion of the disc providing sufficient pressure and resistance for the formation of the casting. Said disc, with the finished casting thereon, is then removed and a new one substituted for repetition of the same operation. As in the previous case, the cool die prevents the heated metal on the edge of the disc from sticking thereto.

I have shown in this modification a device for feeding a powdered carbonized material to the fusing metal for hardening the metal and casting which obviously could be employed in the preferred form of apparatus, if so desired. A hopper 93 for holding the powdered carbonized material 94 is fastened to a wall of the chamber by brackets 95. This hopper interconnects with a feed tube 9% directed toward the peripheral edge of the disc or roller 61. The passageway between the hopper and tube may be open orclosed by a handled spindle or plunger 8l. When the edge of the disc or roller 6'! has reached the desired degree of plasticity the carbonized material is permitted to fall thereon by opening the connection between the hopper and feed tube 96, the disc or roller 61 being continuously rotated by the crank lli, as is manifest.

The invention claimed is:

1. In an apparatus of the character described, a casing having a work chamber, means for supporting in said chamber a solid mass of material from which a casting is to be produced, a die in the chamber, said die and supported body of material being normally disposed in spaced relationship, a device movable into and out of working position in the chamber for fusing a portion of said material, and means for relatively moving the supporting means and die to bring the die and fused portion of the material into contact to form the casting.

2. In an apparatus of the character described, a casing having a work chamber, means for supporting in said chamber a solid mass of material from which a casting is to be produced, means carried by the casing for rotating said supporting means and material, a die in the casing, said die and supported body of material being normally disposed in spaced relationship, a heating device movable into and out of working position in the chamber, for fusing an edge of said material, and means for relatively moving the supporting means and die to bring the die and 'fused portion of the material into contact to form the casting.

3. In an apparatus of the character described, a normally closed chamber, a support in the chamber for the material from which a casting is to be produced, means for rotating said support, means for fusing an edge of said material, a die in said chamber for action on the fused material, and means for bringing the die and fused edge of the material into cooperative relation to form the casing, a sight device mounted in sealing engagement with a Wall of the chamber for permitting visual inspection of the material during the fusing operation.

4. In an apparatus of the character described, a chamber, a support in the chamber for the material from which a casting is to be produced, means for rotating said support, a hopper containing a powdered carbonizing chemical mounted on said chamber and provided with an outlet adjacent the material, means for opening or closing the outlet, means for fusing a portion of the material and a die for receiving said fused portion to form a casting,

5. In an apparatus of the character described, a casing providing a work chamber, a holder for supporting a metallic rod forming a work piece from which a casting is to be produced, said holder supporting said metallic rod for longitudinal feed movement in the chamber, means for rotating said holder, a detent for engagement with said holder for retaining it in one position against longitudinal feed movement, means mounted in the casing for fusing a portion of the rod disposed within the chamber, a die in the chamber, and means for releasing said holder for longitudinal feed movement toward the die to cause the fused metal to enter the die and to be compressed by said rod.

6. In an apparatus of the character described, a casing providing a chamber, a holder for supporting a metallic rod forming a work piece from which a casting is to be produced, said holder being mounted for downward travel in the casing to impart feed movement to said rod, a detent engaging said holder for retaining it in raised position in the chamber, a sleeve splined to said holder, a, pinion carried by said sleeve, a reciprocatory rack mounted on the casing and engaging said pinion and adapted by movement thereof to rotate said sleeve and holder, means for fusing a portion of said rod, a die in the chamber, and means for releasing said detent tov permit said holder to move to bring the fused portion of the L rod into contact with said die.

'7. In an apparatus of the character described, a casing providing a work chamber, a holder for supporting a metallic rod forming a work piece from which a casting is to be produced, said holder mounting said metallic rod for downward travel in the chamber, a detent engaging said holder for retaining it in raised position in the chamber, means urging movement of said holder downwardly in the chamber against the action of said detent, a sleeve connected to said holder while permitting longitudinal movement of said holder therein, means for rotating said sleeve and holder, means for fusing a portion of said metallic rod, a die in the chamber, and means for releasing said detent to permit said holder to move downwardly -to bring the fused portion of the metal rod in contact with the die toform the casting.

8. In an apparatus of the character described, a casing providing a work chamber, a holder for supporting a metallic rod forming a work piece from which a casting is to be produced, said holder mounting the rod for downward movement within the chamber, an electrode, a source of current supply connected to said rod and electrode for establishing an electric heating arc therebetween to fuse a portion of said rod, a die in the chamber, a detent for retaining said holder and rod normally elevated in the chamber and spaced from said die, and means for varying the distance of said electrode from said rod and for releasing said detent to allow said holder to move downwardly into the chamber to bring the fused portion of the metal into contact with said die.

9. In an apparatus of the character described, a casing providing a work chamber, a holder for supporting a metallic rod forming a work piece from which a casting is to be produced, a holder mounting said rod for downward 'travel within said chamber, a slidable electrode mounted in a wall of said chamber, a source of current supply connected to said rod and electrode for establishing an electric arc to effect a fusing of a portion of the rod, a detent detachably locking said holder against downward'movement, a die movable into and out of alignment with the path of downward travel of said rod, and means for reciprocating said electrode toward and from the rod, locking the holder and rod against downward movement and releasing the same for downward movement and moving said die into and out of the path of downward travel of the rod.

JOSEPH E. JOHNSON 

